Compressed air system monitoring and analysis

Abstract

Techniques are disclosed for providing robust, comprehensive measurement and analysis for optimizing efficiency of compressed air systems. The techniques provided can be implemented, for example, in a network appliance local to the target compressed air system, and/or in a server configured to remotely monitor and evaluate the target system. On-site data logging as well as on-site or remote data analysis can be enabled, along with onboard data consolidation. Meters (e.g., airflow, air pressure, power, and/or acoustic) are deployed at the target system and provide data upon which the analysis is based.

1 . A data logging network appliance (DLNA) device, comprising:
 a data logger for logging parameters associated with a compressed air system deployed at a facility; and   a consolidation module for consolidating logged data.   
     
     
         2 . The device of  claim 1  further comprising:
 a data analysis module for analyzing the logged data for unexpected data.   
     
     
         3 . The device of  claim 2  wherein in response to detecting unexpected data, the data analysis module causes an alert to be issued. 
     
     
         4 . The device of  claim 1  further comprising:
 a data analysis module for establishing an airflow-to-power consumption profile of the compressed air system, wherein the profile is based on actual power consumed by the system, airflow required by the facility, and air pressure provided to the facility.   
     
     
         5 . The device of  claim 1  further comprising:
 a data analysis module for optimizing supply of compressed air to the compressed air system with a refined view of compressed air usage based on reduced demand, by identifying air compressors and/or supply-side equipment that are properly sized for the compressed air system.   
     
     
         6 . The device of  claim 1  wherein the data logger is adapted to receive data from one or more airflow meters, and one or more power meters. 
     
     
         7 . The device of  claim 6  wherein the data logger is further adapted to receive data from at least one of an air pressure meter and an ultrasonic acoustic detector. 
     
     
         8 . The device of  claim 1  wherein the device is capable of operatively coupling to a network and communicating with a remote server. 
     
     
         9 . The device of  claim 1  wherein the onboard consolidation module is configured to compute a single data value that is representative of all data samples collected during a designated time interval. 
     
     
         10 . The device of  claim 9  wherein the single data value is an average value of all data samples collected during a designated time interval. 
     
     
         11 . The device of  claim 1  wherein the onboard consolidation module is configured to compute at least one of average, median, mode, minimum, and maximum values for a set of data samples collected during a designated time interval. 
     
     
         12 . A data logging network appliance (DLNA) device, comprising:
 a data logger for logging parameters associated with a compressed air system deployed at a facility, wherein the data logger is adapted to receive data from one or more airflow meters, one or more air pressure meters, and one or more power meters;   a consolidation module configured to compute at least one of average, median, mode, minimum, and maximum values for a set of data samples collected during a designated time interval;   a data analysis module for analyzing the logged data for unexpected data; and   a network interface for operatively coupling to a network and communicating consolidated values computed by the consolidation module to a remote server.   
     
     
         13 . The device of  claim 12  wherein in response to detecting unexpected data, the data analysis module causes an alert to be issued. 
     
     
         14 . The device of  claim 12  wherein the data logger is further adapted to receive data from an ultrasonic acoustic detector. 
     
     
         15 . The device of  claim 12  wherein the data logger is further configured to compute an average value of all data samples collected during the designated time interval, and a plurality of such average values are reported to the remote server. 
     
     
         16 . The device of  claim 12  wherein at least one of the device or the remote server is capable of establishing an airflow-to-power consumption profile of the compressed air system, and for optimizing supply of compressed air to the compressed air system with a refined view of compressed air usage based on reduced demand, by identifying air compressors and/or supply-side equipment that are properly sized for the compressed air system, wherein the airflow-to-power consumption profile is based on actual power consumed by the system, airflow required by the facility, and air pressure provided to the facility. 
     
     
         17 . A method for monitoring and analyzing a target compressed air system deployed at a facility, comprising:
 establishing an airflow-to-power consumption profile of the target system, wherein the profile is based on actual power consumed by the system, airflow required by the facility, and air pressure provided to the facility;   reducing demand associated with the target system; and   optimizing supply of compressed air to the target system with a refined view of compressed air usage based on reduced demand, by identifying air compressors and/or supply-side equipment that are properly sized for the target system.   
     
     
         18 . The method of  claim 17  where reducing demand associated with the target system comprises:
 identifying at least one of leaks and inappropriate uses of compressed air, to assist in reducing overall target system air pressure.   
     
     
         19 . The method of  claim 17  wherein the method further comprises providing consolidated data collected at the facility to a remote server where the establishing and optimizing is carried out. 
     
     
         20 . The method of  claim 17  wherein the method further comprises at least one of:
 measuring resultant airflow, air pressure, and power consumption to verify that performance objectives are achieved after optimizing; and   reporting identified air compressors and/or supply-side equipment to the facility.